Hydrogen gas generator

ABSTRACT

A hydrogen generating device comprising an anode, a cathode, a housing having an internal cavity and a perforated wall within the cavity electrically connected to the anode or the cathode and separating an end portion of the cavity from a main portion of the cavity. The device includes water in the housing extending continuously from the main portion of the cavity through the perforated wall and into the end portion of the cavity. The housing includes two ends and a perforated wall within the cavity near each end separating end portions of the cavity from a main portion of the cavity, the anode or the cathode extending through one end of the housing through one perforated wall into the main portion of the cavity, through the other perforated wall into the other end portion of the cavity and through the other end of the housing.

This application is a continuation application of pending U.S. patentapplication Ser. No. 13/099,707 filed May 3, 2011, which is herebyincorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to hydrogen gas generators for theproduction of hydrogen gas.

2. Description of Related Art

Hydrogen generators produce a mixture of hydrogen (H2) and oxygen (O₂)gases, typically in a 2:1 molar ratio, the same proportion as water.

Hydrogen gas generators include four main components; a cathode, ananode and a salt or brine solution contained within a cavity whichincludes the anode and cathode. The generator usually consists ofstainless steel metal plates stacked with spacing between the plates toallow the brine solution to flow therebetween. An alternating cathodeand anode plate configuration allows current to flow through the brinesalt solution producing a chemical reaction when a voltage differentialis placed between the anode and cathode plates.

The metal plate stack is the most common configuration for a hydrogengas generator. One problem associated with the stacked plates is thatthe fluid between the plates is not easily exchanged with fresh fluidfrom other parts of the generator, decreasing the efficiency of thegenerator.

SUMMARY OF THE INVENTION

Bearing in mind the problems and deficiencies of the prior art, it istherefore an object of the present invention to provide a device for theproduction of hydrogen gas.

It is another object of the present invention to provide a cylindricalhydrogen gas generator which produces hydrogen gas more efficiently thanthe stacked plate generators.

Still other objects and advantages of the invention will in part beobvious and will in part be apparent from the specification.

The above and other objects, which will be apparent to those skilled inthe art, are achieved in the present invention which is directed to ahydrogen generating device comprising an anode, a cathode, a housinghaving an internal cavity and a perforated wall within the cavity nearan end thereof electrically connected to the anode or the cathode andseparating an end portion of the cavity from a main portion of thecavity. The device includes water in the housing extending continuouslyfrom the main portion of the cavity through the perforated wall and intothe end portion of the cavity.

The anode or the cathode which is electrically connected to theperforated wall may extend from the main portion of the cavity throughthe perforated wall into the end portion of the cavity and through thehousing. The housing may have two ends and a perforated wall within thecavity near each end separating end portions of the cavity from a mainportion of the cavity. The anode or the cathode extend through one endof the housing through one perforated wall into the main portion of thecavity, through the other perforated wall into the other end portion ofthe cavity and through the other end of the housing. The water in thehousing extends continuously from the main portion of the cavity througheach of the perforated walls and into the end portions of the cavity.

The perforated wall may be a metal plate having openings therein or maybe an open cell metal foam. The hydrogen generating device may include acylindrical metal sleeve slidingly disposed within the internal cavity,the metal sleeve having ends, and an insulating spacer ring disposedbetween the metal sleeve ends and the perforated wall.

The anode may be a hollow metal tube spirally wound in a cylindricalconfiguration. The anode may alternately be a hollow metal cylinderwhich includes a plurality of anode openings through the cylinder wallsor the anode may be a cylindrical wire mesh.

The hydrogen generating device may include at least one electricallyconductive terminal extending outward from the cavity through an openingin the housing wherein the at least one terminal is in electricalcontact with the anode.

Another embodiment the present invention is directed to a hydrogengenerating device comprising a housing having an internal cavity, ananode within the internal cavity and a cathode within the internalcavity. The device includes an open cell metal foam disposed within theinternal cavity electrically connected to the anode or the cathode. Thedevice includes water in the housing extending continuously through themetal foam. The open cell foam may be the anode having channels thereinwith the cathode extending through the channels in the foam anode. Theanode channels may have a length and channel walls with a space betweenthe cathode and channel walls extending the length of the channel walls,the space substantially filled with the water.

The open cell foam may alternately be the cathode having channelstherein, with the anode extending through the channels in the foamcathode. The hydrogen generating device may include a cylindrical metalsleeve slidingly disposed within the internal cavity. The metal sleevemay have ends wherein an insulating spacer ring is disposed between themetal sleeve ends and the perforated wall.

The metal foam may include a coating of gold metal.

Another embodiment the present invention is directed to a method forusing a hydrogen generating device. The method comprises providing ananode, a cathode, a housing having an internal cavity and a perforatedwall within the cavity near an end thereof separating an end portion ofthe cavity from a main portion of the cavity. The anode or the cathodeextends from the main portion of the cavity through the perforated wallinto the end portion of the cavity and through the housing and water inthe housing extending continuously from the main portion of the cavitythrough the perforated wall and into the end portion of the cavity. Themethod includes applying a voltage differential between the anode andcathode sufficient to allow production of hydrogen gas.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the invention believed to be novel and the elementscharacteristic of the invention are set forth with particularity in theappended claims. The figures are for illustration purposes only and arenot drawn to scale. The invention itself, however, both as toorganization and method of operation, may best be understood byreference to the detailed description which follows taken in conjunctionwith the accompanying drawings in which:

FIG. 1 is an exploded perspective view of the hydrogen gas generatoraccording to the present invention.

FIG. 2 is a cross sectional view of an anode terminal and terminalinsulator according to the present invention.

FIG. 3A is an elevational end view of the hydrogen gas generator of FIG.1 with the endcap removed.

FIG. 3B is an elevational end view showing an alternate configuration ofterminals and ports extending through the housing of the hydrogen gasgenerator according to the present invention.

FIG. 4 is a perspective view of the anode of the hydrogen gas generatorof FIG. 1.

FIG. 5 is a perspective view of a second embodiment of the anodeaccording to the present invention.

FIG. 6 is a perspective view of a third embodiment of the anodeaccording to the present invention.

FIG. 7 is a perspective view of a fourth embodiment of the anodeaccording to the present invention.

FIG. 8 is a cutaway view of a hydrogen gas generator including the anodeshown in FIG. 7.

FIG. 9 is a side elevational view of a hydrogen gas generator shown inFIG. 8.

FIG. 10 is cross sectional end view of a hydrogen gas generator showingthe connection of the anode terminals to the anode shown in FIG. 5.

FIG. 11 is a side elevational view of a hydrogen gas generator includinga reservoir system according to the present invention.

FIG. 12 is a block diagram of a valve system for controlling gas outputaccording to the present invention.

FIG. 13 is a block diagram of a controller for the hydrogen gasgenerator according to the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

In describing the preferred embodiment of the present invention,reference will be made herein to FIGS. 1-13 of the drawings in whichlike numerals refer to like features of the invention.

A hydrogen gas generator 10 shown in FIG. 1 includes a cylindricalceramic coated aluminum housing 14 having housing openings 16 and acylindrical metal sleeve 22 slidingly disposed inside the housing 14,the metal sleeve 22 being shorter in length than the housing 14. Thehousing 14 has opposing ends and a cavity between the ends and aperforated wall 30 is abuts the ends of metal sleeve 22 and is spacedfrom and near each of the housing ends. The metal sleeve 22 includesnon-insulated sleeve openings 26 and insulated sleeve openings 28. Thenon-insulated openings 26 are for engaging an inlet port 12 and a drainport 13 for the brine solution, a hydrogen gas outlet port 80 and apurge valve port 82. The insulated sleeve openings 28 are for anodeterminals 11 which extend from outside the housing 14 to the anodeinside the cylindrical metal sleeve 22. Terminal insulators 32 aredisposed between the anode terminal 11 and the insulated sleeve openings28 as shown in the cross sectional view of FIG. 2. Ends of the anodeterminals 11 protrude from the terminal insulators 32 so that electricalconnection can be made to the anode 18 inside the cavity and to a powersupply external to the cavity. The metal sleeve 22 openings align withthe housing openings 16 so that the terminals 11 and each of the drainport 13, inlet port 12, hydrogen gas outlet port 80 and purge valve port82 extend through the corresponding housing opening 16 and sleeveopenings 26, 28, sealingly contacting the housing 14 and preventingliquid and gas within the cavity from leaking from the cavity throughthe housing openings 16. The hydrogen gas generator anode may be of anysuitable type and configuration, but is shown in FIG. 1 as a cylindricalspiral anode 18. The anode is contacted by terminals 11, which supportit within and spaced from sleeve 22 and the cathode structures withinthe device.

A plurality of cathode rods 20, here shown as a central rod surroundedby four spaced rods, extend from the perforated wall 30 at one end ofthe housing 14 to the opposing perforated wall 30 at the other end ofthe housing, with each cathode rod 20 making electrical contact with thewalls. At each end of the housing 14, a cathode terminal 24 is disposedin a central opening 52 of the perforated wall 30 and extends through anend cap opening 72 in the end cap 70. The cathode terminal 24 may bethreaded so that a terminal nut 74 secures the end cap 70 against theperforated wall 30. The cathode terminal 24 provides a common connectionfor the cathode rods 20 through contact with the perforated wall 30.

The hydrogen gas generator includes an insulating spacer 60 near eachend of the housing 14 and which seats against the sleeve 22 ends so thatperforated wall 30 may be sealed to the sleeve without making electricalcontact. The perforated wall includes a plurality of openings orperforations 50 that extend through the perforated wall. Any number ofopenings or perforations may be employed to permit passage of the brinesolution therethrough.

End caps 70 engage slidingly within the housing 14 ends and contact theperforated wall 30 forming a seal so that, along with seals 60, gas andliquid are prevented from exiting the cavity except through the hydrogenoutlet port 80 or the purge valve 82.

In use, the water contained within the housing cavity containssufficient electrolyte, such as salt (Na⁺Cl⁻) or another electrolyte, toconduct electricity, and may be referred to as a brine solution. When avoltage potential is placed across the anode (+) and cathode (−), theresulting current causes the brine to electrolyze and creates hydrogen(H2) in the form of a gas at the cathode, and oxygen (O₂) in the form ofa gas at the anode. The cathode walls 30 at each end of sleeve 22 createsmall chambers between the perforated walls 30 and the end caps 70 ateach end of housing 14. Although the exact mechanism is not known, it isbelieved that these chambers holding the brine in communication with themain cavity significantly aid in the generation of usable hydrogen bythe device.

FIG. 3A shows an end view of the hydrogen gas generator with the end cap70 removed. The terminals 11 and each of the drain port 13, inlet port12, hydrogen gas outlet port 80 and purge valve port 82 extend from thehousing 14 in radially opposite direction as shown in FIG. 1. FIG. 3Bshows an alternate arrangement where the housing openings are notaligned in straight rows on opposite sides of the housing. Thearrangement may be additionally changed depending on the orientation ofthe hydrogen gas generator or other factors for implementation of thehydrogen gas generator.

FIGS. 4-6 show various embodiments of the anode, FIG. 4 being theembodiment of the anode shown in FIG. 1 wherein the anode 18 is a hollowmetal tube spirally wound in a cylindrical configuration and having theends crimped closed. In another embodiment the anode 18′ shown in FIG. 5is a hollow metal cylinder which includes a plurality of anode openings44 through the cylinder walls. Anode 18″ shown in FIG. 6 is acylindrical wire mesh. Anodes 18, 18′ and 18″ are supported within thecavity of housing 14 by contact with anode terminals 11.

In another embodiment of the present invention shown in FIG. 7-9, thehydrogen generator 10′ includes a cylindrical open cell metal foam anode86 having bore holes or channels 88 extending the length of the anode86. The cathode rods 20 are disposed through the holes 88 with at leastone of the cathode rod ends extending beyond the corresponding end ofthe cylindrical anode 86. Alternatively, the cathode may be in the formof the open cell metal foam and the anode may be in the form of rodsextending through the openings therein. The bore holes 88 have adiameter sufficiently sized so that such that the rods 20 do not contactthe metal foam 86. The open cells of the metal foam allow brine or water90 to flow freely through the cells from one side of the anode to theother. The cutaway view of FIG. 8 includes portion A showing the housing14, portion B with the housing cut away to show the metal sleeve 22,portion C with the metal sleeve cut away to show the outside surface ofthe metal foam 86 and portion D with the outside surface of the metalfoam cut away to show the inside surface of the metal foam 86′ and thecathode rods 20. The metal foam is preferably an aluminum metal foam andmay include a gold metal coating to prevent corrosion. Aluminum metalfoam may be aluminum throughout the foam or may be a poly foam withaluminum coating applied over the foam. The anode 18, cathode rods 20and sleeve 22 of the may additionally include a gold metal coating toprevent corrosion. An exemplary gold marine coating that may be appliedto the anode, cathode, and other components of the hydrogen generator ofthe present invention is the coating sold under the brand name JET-HOTnPowered by nCoat LLC of Burlington, N.C. The coating may be asilica-based nano-ceramic organic hybrid, applied as either an aqueous-or solvent-based liquid by spraying, dipping, rolling or dip-spinmethod, and cured at an elevated temperature of 120-180° C. for 10minutes or a time sufficient to bond and cure the coating to a desiredthickness, e.g., 1-2 micrometers. An example is NanoMate coatingavailable from Nanmat Technology of Kaohsiung, Taiwan.

FIGS. 8 and 9 includes a cylindrical ceramic coated aluminum housing 14having housing openings 16 and a metal sleeve 22 slidingly disposedinside the housing 14. The housing 14 has opposing ends and a cavitybetween the ends and a perforated wall 30′ is disposed near each of thehousing ends. The perforated wall 30′ is shown as a plate made from anopen cell metal foam. Terminal insulators 32 are disposed between theanode terminal 11 and the metal sleeve 22. Ends of the anode terminals11 protrude inwardly from the terminal insulators 32 so that mechanicaland electrical connection can be made to the anode 18 inside the cavityand outwardly for connection to a power supply external to the cavity.The hydrogen gas generator 10′ includes an end cap 70 with at least aportion of the endcap disposed slidingly inside the housing 14 end and acathode terminal 24 disposed through the an opening 72 in the endcap 70.The cathode terminal 24 electrically contacts the metal foam perforatedwall 30′ inside the housing and a voltage supply outside of the housing.

FIG. 9 is an assembled hydrogen gas generator 10′ which includes the endcaps 70 secured so that brine or water 90 within the cavity may flowfreely within the cavity but not leak out. Drain port 13 allows thebrine or water to flow out of the housing cavity when the port is in anopen position and prevents flow when in the closed position. Inlet port12 allows the brine or water to flow into the housing cavity when theport is in an open position and prevents flow when in the closedposition.

FIG. 10 shows the anode 18′ supported within the housing cavity by anodeterminals 11 and anode washers 34. The washers 34 are attached to theanode terminals 11 and contact the outer wall of the anode 18′,preventing the anode 18′ from moving with respect to the housing 14. Theanode terminal 11 is fastened to the housing 14 with an insulatingo-ring 32′.

FIG. 11 shows the hydrogen gas generator 10 connected to a reservoirsystem for flushing the brine solution within the housing cavity. Thehousing may include a transparent window 46 for visual monitoring of thegenerator activity inside. The reservoir system includes a reservoirtank 58, feed line 62 for flowing solution 59 from the tank 58 to thegenerator through valve 67. The system also includes a return line 64,return valve 68 and a pump 66 for pumping the brine solution 59 throughthe generator and tank.

FIG. 12 shows components which are attached to the hydrogen gasgenerator for controlling and sensing the gas output from generatoroutlet 80 (FIG. 1). The components include valve 124 for controlling thehydrogen gas flowing from the outlet 80 to a caustic bubbler 38. Theoutlet of the bubbler 38 includes a drain valve 126, hydrogen outletvalve 122 and a Hobb switch 128. The Hobb switch 128 is a pressuresensing switch which includes a relay which engages when the pressureexceeds a given value. The Hobb switch may be used to close a safetycircuit and turn off operation of the hydrogen gas generator if thehydrogen gas pressure exceeds a safe value.

FIG. 13 shows a block diagram of a controller for the hydrogen gasgenerator. The controller includes a central processing unit 100 andinputs from the gas generator or from the control components shown inFIG. 12 which include input 102 from the Hobb switch 128 and input 104from a pressure gauge on the gas generator housing. The controlleroutputs include output 110 which sends an electrical output forcontrolling the drain port, output 112 for controlling power to theanode and cathode terminals, output 116 for controlling pump 66 andoutput 118 for controlling the flush valves 67, 68. The controlleroutputs may also include a safety shut-off 114 and hydrogen gas control120 for controlling valve 124.

The anode is preferably aluminum although other metals may be used. Thecathode rods are preferably stainless steel although other metal may beused. The anode and cathode structures may be interchanged and/orreversed in the hydrogen gas generator of the present invention.

In operation, brine or water 90 is injected into the cavity of thehydrogen gas generator 10 and a voltage differential is applied betweenthe anode and cathodes, breaking down and electrolyzing the water insideof the cylinder. The chemical reaction produces hydrogen and oxygen gasand may produce other byproducts including hydroxide, chlorine andcaustic soda. The hydrogen gas that is produced is allowed to exit thehydrogen gas outlet 80, while the purge valve 82 is provided for purgingother gas or water from the cavity of the housing 14.

The hydrogen gas generator of the present invention has overcome thedeficiency of the prior art by implementing a perforated wall whichsufficiently separates the main housing cavity from the end chambers butallowing the brine to flow from the cavity to the end chamber and theend chamber to the cavity.

While the present invention has been particularly described, inconjunction with a specific preferred embodiment, it is evident thatmany alternatives, modifications and variations will be apparent tothose skilled in the art in light of the foregoing description. It istherefore contemplated that the appended claims will embrace any suchalternatives, modifications and variations as falling within the truescope and spirit of the present invention.

Thus, having described the invention, what is claimed is:
 1. A hydrogengenerating device comprising: a housing having an internal cavity; acathode within the internal cavity; an anode within the internal cavity;a sleeve slidingly disposed within the internal cavity; and water in thehousing extending continuously from a main portion of the internalcavity to an end portion of the internal cavity.
 2. The hydrogengenerating device of claim 1 further including a perforated wall withinthe internal cavity near the end portion of the internal cavity, theperforated wall being electrically connected to the anode or the cathodeand separating the end portion of the internal cavity from the mainportion of the internal cavity.
 3. The hydrogen generating device ofclaim 2 wherein the sleeve has ends and an insulating spacer disposedbetween the sleeve ends and the perforated wall.
 4. The hydrogengenerating device of claim 2 wherein the anode or the cathodeelectrically connected to the perforated wall extends from the mainportion of the internal cavity through the perforated wall into the endportion of the cavity and through the housing.
 5. The hydrogengenerating device of claim 2 wherein the perforated wall is a metalplate having openings therein.
 6. The hydrogen generating device ofclaim 2 wherein the perforated wall is an open cell metal foam.
 7. Thehydrogen generating device of claim 1 wherein the housing has two endportions and a perforated wall within the internal cavity near andseparating each end portion of the internal cavity from the main portionof the internal cavity, the anode or the cathode extending through oneend portion of the housing through one perforated wall into the mainportion of the internal cavity, through the other perforated wall intothe other end portion of the internal cavity and through the other endof the housing, the water in the housing extending continuously from themain portion of the internal cavity through each of the perforated wallsand into the end portions of the internal cavity.
 8. The hydrogengenerating device of claim 1 wherein the cathode comprises a metal foam.9. The hydrogen generating device of claim 1 wherein the anode comprisesa metal foam.
 10. The hydrogen generating device of claim 1 wherein theanode comprises a hollow metal tube spirally wound in a cylindricalconfiguration.
 11. The hydrogen generating device of claim 1 wherein theanode is a hollow metal cylinder or a cylindrical wire mesh.
 12. Thehydrogen generating device of claim 1 wherein the sleeve comprises ametal sleeve slidingly disposed within the internal cavity.
 13. Thehydrogen generating device of claim 12 wherein the metal sleevecomprises a cylindrical metal sleeve.
 14. The hydrogen generating deviceof claim 1 including at least one electrically conductive terminalextending outward from the internal cavity through an opening in thehousing, wherein the at least one terminal is in electrical contact withthe anode.
 15. A hydrogen generating device comprising: a housing havingan internal cavity; an open cell metal foam disposed within the internalcavity for providing an electrical current therein; a sleeve slidinglydisposed within the internal cavity; and water residing in the housingextending continuously through the open cell metal foam.
 16. Thehydrogen generating device of claim 15 wherein the open cell foam is ananode having channels therein, whereby a cathode extends through thechannels in the open cell foam anode.
 17. The hydrogen generating deviceof claim 16 wherein the open cell foam anode channels have a length andinclude channel walls with a space between the cathode and channel wallsextending the length of the channel walls, the space substantiallyfilled with the water.
 18. The hydrogen generating device of claim 15wherein the open cell foam is a cathode having channels therein, wherebyan anode extends through the channels in the open cell foam cathode. 19.The hydrogen generating device of claim 15 wherein the sleeve comprisesa metal sleeve slidingly disposed within the internal cavity.
 20. Amethod for using a hydrogen generating device comprising: providing ahousing having an internal cavity with an anode and cathode therein,along with a sleeve slidingly disposed within the internal cavity of thehousing, the housing having water residing continuously therein from amain portion of the internal cavity to an end portion of the internalcavity; and applying a voltage differential between the anode andcathode sufficient to allow production of hydrogen gas.